Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. For additional information, Refer to FUEL SYSTEM - GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, Refer to BATTERY, MOUNTING AND CABLES .
Remove the rear seat lower cushion. For additional information, Refer to SEATING .
Remove the Fuel Pump (FP) module access cover, located on the RH side floor pan.
If equipped, remove the 3 nuts and the FP module shield.
NOTE: To avoid introducing contamination into the fuel tank use compressed air to clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.

Disconnect the electrical connectors.
Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector.
Disconnect the fuel tank quick connect couplings. For additional information, Refer to FUEL SYSTEM - GENERAL INFORMATION .
Attach the Fuel Storage Tanker tube to the FP module outlet fitting and remove one fourth (approximately 5 gallons) of the fuel from a completely full tank, lowering the fuel level below the FP module mounting flange.
NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring.

Install the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

Carefully lift the FP module out of the fuel tank to access and disconnect the FP module internal fuel tube-to-FP module quick connect coupling and the transfer tube quick connect coupling, if equipped. For additional information, Refer to FUEL SYSTEM - GENERAL INFORMATION .

NOTE: AWD shown in illustration, FWD similar.
NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.

Completely remove the FP module from the fuel tank.
Remove and discard the FP module O-ring seal.
NOTE: The FP module must be handled carefully to avoid damage to the float arm.

NOTE: Inspect the mating surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Wipe clean with a lint free towel. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: Sweep the float arm to ensure freedom of travel.

NOTE: Make sure to install a new FP module O-ring seal.

Install a new O-ring seal.
Loosely install a 12" (minimum length) zip-tie to the internal fuel tube at the quick connect coupling. Leave the tail of the zip tie on to allow the tube to be retrieved while the FP module is being installed.
NOTE: Make sure the alignment tab on the FP module and the fuel tank meet before tightening the FP module lock ring.

Install the FP module by inserting the float rod through the Fuel Tank opening. Connect the transfer tube quick connect coupling at the bottom of the FP module, if equipped. Then, use the zip tie to help retrieve and connect the internal fuel tube to the FP module as it is installed into the fuel tank. For additional information, Refer to FUEL SYSTEM - GENERAL INFORMATION . Remove the zip tie.
NOTE: Install a new lock ring if it is bent, damaged or corroded.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when tightening the lock ring.

Install the Fuel Tank Sender Unit Wrench and tighten the fuel tank lock ring by turning clockwise.
Connect the fuel tank quick connect couplings. For additional information, Refer to FUEL SYSTEM - GENERAL INFORMATION .
Connect the FP module electrical connector.
If equipped, install the FP module shield.
- To install, tighten to 9 Nm (80 lb-in).
Install the Fuel Pump (FP) module access cover.
Install the rear seat lower cushion. For additional information, Refer to SEATING .
Connect the battery ground cable. For additional information, Refer to BATTERY, MOUNTING AND CABLES .